CnW Maintenance Manual - Bogies and Suspension - PDF

CHAPTER 6 - BOGIES AND SUSPENSION Page 1 of 43 CHAPTER 6 BOGIES AND SUSPENSION 601. CASNUB BOGIE 601A. GENERAL DESCRIPTION This bogie was first fitted in BOXN wagons and was desi...

CHAPTER 6 - BOGIES AND SUSPENSION Page 1 of 43 CHAPTER 6 BOGIES AND SUSPENSION 601. CASNUB BOGIE 601A. GENERAL DESCRIPTION This bogie was first fitted in BOXN wagons and was designated as CASNUB 22W. This was later modified as CASNUB 22W(M) to take care of high wheel wear reported on earlier version. Subsequently CASNUB 22NL (Narrow jaw) and CASNUB 22 NLB (Narrow jaw with fish belly bolster) versions were introduced. The CASNUB 22 HS and CASNUB 22HS (Mod-I) bogies have been developed for high- speed operation with maximum permitted speed up to 100 km/h at 20.32t axle load. All CASNUB 22W bogies were to be converted to CASNUB 22W (Retrofitted) by the maintenance depots and workshops. The various bogie versions developed thereafter, are as under and are now used in the following wagons:- The bogies of type 22W, 22W retrofitted have been phased out considerably hence details of these have not been included in this manual. For details of this type of bogies 2001 version of WMM may be referred. Bogie Axle Load Type of Wagon BOXN, BOXNM1, BCN, BCNM1, CASNUB -22 NLB 20.32t & BCNA, BCNAM1, BOBR, BOBRM1, BOBRN, BOBRNM1, BRN, BRNA, 22.9t BTPN, BTAP, BTPGLN, BOBYN, BOBSN, BOY, BCCW, BRSTN, BWTB, BOMN etc and M1 variant. CASNUB -22HS 20.32t & BOXNHS, BOXNHSM1, BOXNLWM1, 22.82t BCNHS, BCNHL, BCCW, BCNAHS BOBRNHS, BRNHS, BRN22.9, BRHNEHS, BOSTM1, BOBYN22.9, BOST, BOXNHL BOXNLW, BFNS etc and M1 variant of above. CASNUB -22HS (Mod-I) 20.32t & BOSTHS, BOSTHS M1,BCBFG 22.32t CASNUB -22HS(Mod-II) 22.32 t BOSTHS M2 CASNUB -22 NLC 25.0 t BOBRNEL, BOYEL, BOXNEL, BOBSNM1 IRF-108HS 22.82 t BOXNHAM, BOXNHA, BOXNR, BCCN LCCF 20(C) 20.32 t BLLA/B, BLCA/B, BLCAM/BLCBM, 22.0 t BCACM, BCACBM The wagon list given above is for reference only and is not exhaustive. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 2 of 43 601 B. CONSTRUCTIONAL DETAILS The bogie comprises of two cast steel frames and a floating bolster. The bolster is supported on the side frame through two nests of springs. This also provides a friction damping proportional to load. A fabricated mild steel spring plank connects the side frames. 2000 (WHEEL BASE) 2260 (JOURNAL CENTRES) BOGIE GENERAL ARRANGEMENT CASNUB 22 NLB BOGIE FIG. 6.1 BOGIE GENERAL ARRANGEMENT CASNUB 22 NLB WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 3 of 43 The salient features of components fitted in different types of CASNUB bogies are given below. Sr. No Features Description 1. Gauge 1676 mm 2. Axle load Modified CASNUB 22HS(Mod-I) -22.32t CASNUB 22HS(Mod-II) -22.32t CASNUB 22NLC -25t IRF 108HS -23.5 t All other bogies- 20.32 t, However these can be upgraded to CC+8t+2t with certain changes in the suspension. 3. Wheel diameter 1000 mm (New) 906 mm (Condemn) for all except CASNUB 22NLC 955 mm (Min) for CASNUB 22NLC 4. Wheel base 2000 mm 5. Type of Axle bearing Cartridge Tapered Roller Bearing Class „E‟ suitable for narrow jaw/ wide jaw adapter 6. Distance between 2260 mm journal centres 7. Distance between 1474 mm side bearers 8. Type of side bearers RDSO Approved Constant contact type side bearers. 9. Type of pivot CASNUB 22W(M), 22NL 22NLB, 22NLM, 22 HS, 22NLC and IRF-108HS - Spherical Type RDSO Drg. No. WD-85079-S/2 CASNUB 22HS, HS(Mod-I), HS(Mod-II) Flat Type RDSO Drg. No. WD-97049-S/3 10. Anti-rotation features Anti-rotation lugs have been provided between bogie bolster and side frame 11. Type of brake beam All bogies except CASNUB 22W (M): Unit type fabricated brake beam supported and guided in the brake beam pockets. CASNUB 22W (M): Unit Type Cast Steel brake Beam suspended by hangers from side frame brackets. 12. Suspension details Long travel helical spring 13. Elastomeric pads On all types of bogies. The CASNUB bogie assembly consists of the following components: i. Wheel set with Cartridge Bearing ii. Axle Box/ adapter, retainer bolt & side frame key assembly iii. Side frames with friction plates and brake wear plates iv. Bolster with wear liners v. Spring plank, fit bolts & rivets vi. Load bearing springs and snubber springs vii. Friction shoe wedges WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 4 of 43 viii. Centre pivot arrangement comprising of Centre pivot top, Centre pivot Bottom, Centre pivot pin, Centre pivot retainer & locking arrangement ix. Side Bearers x. Elastomeric Pad xi. Bogie Brake Gear xii. Brake Beam The details of above components are as under:- a) WHEEL SET WITH CARTRIDGE TAPERED ROLLER BEARING CASNUB bogie are fitted with Class “E” Cartridge Tapered Roller Bearings (CTRB) (6”X11”). Maintenance requirement of cartridge taper roller bearing have been issued under “Instruction for inspection and maintenance of Cartridge Taper Roller Bearing fitted on Cast Steel Bogies”, Technical Pamphlet No. G-81of RDSO. Bearings that have been serviced during POH or otherwise because of re-discing, hot box, accident etc. have to be permanently and legibly marked overhauling particulars on the Cup/Outer ring (on the straight portion in the centre between the raceways) and also on the backing ring as per details/drawing shown in Appendix-IV „A‟.However, for detailed maintenance and inspection of CTRB in open line, Handbook on Maintenance of CTRB for freight stock issued under CAMTECH Doc. No. IRCAMTECH/M/12-13/Bearing/1.0, December-20 12 may be referred. Wheel tread/tyre profile used earlier was standard 1 in 20 taper after the root radius. Currently a worn wheel profile or worn adapted profile has been prescribed to reduce wheel wear and increase wheel life. The tyre/ tread profile for new wheel is as per Drg No. WD-88021. As per requirement, during POH/ROH/Maintenance of wheel set/wheel re-profiling, wheels tread should be turned as per intermediate profile having varying wheel flange thickness selecting the appropriate flange thickness out of the nine flange thicknesses so that minimum material is removed at the time of turning. These intermediate profiles have been incorporated to optimise the wheel life. These are as per Drg. No. WD-89060- S/2. Wheel diameter for new wheel is 1000 mm. Condemning wheel dia is 906 mm for all versions except CASNUB 22NLC Bogie. Minimum wheel dia for CASNUB 22NLC bogie is 955 mm. b) AXLE Axles have to be subjected to ultrasonic testing during ROH/POH or whenever the wagons are sent to the shops. Wheel sets whose axles have under gone ultrasonic testing shall be stamped on the hub fillet as per RDSO‟s drawing no. WD-81089-S/1 (attached at Appendix –IV ‘C). Axle end holes should be properly cleaned and lubricated before reuse. Threads should be checked with standard thread gauge. Reclamation of axles WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 5 of 43 with defective cap screw holes shall be carried out as per instructions given in RDSO letter MW/WA/Genl dated 8.5.92. Some axles on CASNUB bogies have been reported to have grazing on account of Main pull rod. This can be reclaimed in case notches/scratch/nicks are less than 5 mm as per instructions issued vide RDSO‟s letter No. MW/WA/GENL dated 20.12.91. The reclamation of the axle, for reasons not indicated in the above quoted letter, is not permitted. Whenever axles are renewed, the workshop shall punch the following particulars in 5 mm letters on the axle end:- i. Serial No. ii. Workshop code where pressing has been done iii. Date of pressing iv. Pressing on pressure in tonnes (Both ends) After rediscing, the stamping shall be as per RDSO Drg No. WD- 87080/S-1. c) ADAPTER OF CTRB, RETAINER BOLT & SIDE FRAME KEY ASSEMBLY CASNUB 22W & CASNUB 22W (M):- Wheel sets of these bogies are having Cartridge Tapered Roller Bearing Class „E‟ (6” X 11”) with Wide Jaw adapter to drg. no. SK 78527. In retrofitted CASNUB 22W bogies, modified wide jaw adapter to drg no. WD – 85053 – S/1 is used. All other CASNUB type of bogie except CASNUB 22W, CASNUB 22W (M): – Wheel sets are provided with Cartridge Tapered Roller Bearing Class „E‟ (6” X 11”) with narrow jaw adapter to drg no. WD-89067-S/9. The wear limits are given in Table 6.1. d) SIDE FRAMES WITH FRICTION PLATES Side frame column has been provided with 10 mm thickness Silico Manganese Steel wear liners to IS: 3885 Pt.-I Gr. IV welded on the columns. It must be ensured that the liners permitted in service up to a thickness of 6 mm only. The new friction plate is to be held tight against the column face during welding which should be done in down hand position. Start welding at diagonal ends of the plate and work towards the centre. No paint or grease should be applied on the friction plate. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 6 of 43 The side frame should be checked for its wheelbase (distance between centre lines of the jaw openings) and ensure whether the correct button marking is left on the side frame. While pairing the side frame for a bogie, it should be ensured that there should not be any difference between the numbers of buttons on the two-side frames. The wear limits are given in Table 6.1. e) BOLSTER WITH WEAR LINERS Bolster pocket has been provided with 8 mm thick silico manganese Steel liners welded with pocket slope. The liners may be permitted in service up to a thickness of 3 mm. The welded liners should be chipped off to prepare the surface for welding new liners. No paint or grease should be applied on the plate. Some bogie bolsters such as those of CASNUB 22NLB &22HS bogies have been provided with 5mm thick wear liners on land surfaces & same are to be required to be replaced after 3mm wear. The wear limits are given in Table 6.1. f) SPRING PLANK, FIT BOLTS & RIVETS Spring plank is a member made of mild steel (flanging quality) to IS: 5986 Fe 360. It joins two side frames of CASNUB bogie by eight 24 mm dia rivets and four M24 “fit” bolts to keep bogie frame square. Spring plank should be examined for defects like loosening of rivets/cracks/bending, welding failure of spring spigot etc. Whenever, spring plank is renewed, the leading dimension of the bogie as per Drg no. WD-85054-S/6(22WM), WD-90042-S/1(NL, NLB, NLM, NLC), WD-92058- S/7[HS, HS(Mod-I), HS(Mod-II)] must be measured. Special care is to be taken regarding the use of fit bolts as well as quality of riveting. Fitment of spring plank with side frames should be done on suitable fixture. g) LOAD BEARING SPRINGS AND SNUBBER SPRINGS The bogies are fitted with two groups of long travel helical spring nests. The spring details are shown in following table- Type of bogie Drawing number CASNUB 22 W(M), NL, NLB, NLM, NLC WD-83069-S/1 CASNUB 22HS WD-92058-S/5 CASNUB 22HS(Mod-I) WD-04017-S/4 CASNUB 22HS(Mod-II) WD-08026-S/3 IRF 108HS WD-98014-S/3 LCCF 20(C) WD-11013-S-01 WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 7 of 43 DAMPING The suspension is provided with load proportional friction damping arrangement with the help of manganese steel cast wedge supported on the snubber springs. The springs are manufactured out of silico Manganese steel, chrome vanadium, chrome molybdenum. The matching of load and snubber springs is important. It is recommended that the springs should be so grouped that the free height variation in the group is not more than 3 mm. Mixing of new and old springs should be avoided. The nominal free height and condemning height are given in Table 6.1. h) FRICTION SHOE WEDGES Friction shoe wedges are fitted on snubber springs. Its vertical surface is with side frame and slope surface is in contact with bolster pocket liners. A table containing wear limits on vertical surface and slope surface nominal and recommended is placed at Table 6.1. i) CENTRE PIVOT ARRANGEMENT Centre pivot arrangement for various bogies is as follows - Centre Pivot Arrangement Drawing No CASNUB 22W(M),NL,NLB,NLM,NLC, WD-85079-S/2 CASNUB 22 HS bogies CASNUB 22HS,HS(Mod-I),HS(Mod-II) WD-97049-S/3 IRF 108HS WD-98014-S/4 LCCF 20(C) Note: In CASNUB 22 HS bogies, either a spherical or flat centre pivot can be fitted as applicable. To determine the seat wear, the gauge should be placed in position. If the pivot surface starts touching the surface marked as „*‟ on the gauge at any point, repair to be made by welding. The gauge should be moved on the complete worn surface to be measured. The surface after reclamation shall be the original dimension as per the respective drawings for proper matching of surfaces with top centre pivot. The repairs should be carried out if a 7 mm thick shim in CASNUB bogie can be inserted for the full depth between the worn surface and the gauge at any point on the vertical wall of the bowl with gauge in position. During POH/ROH the wear on the vertical side of the bowl, seat of the bowl should be built up by welding. Preheat the surface to be reclaimed up to a WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 8 of 43 maximum temperature of 250° Celsius. After welding, it should be allowed to cool slowly by covering the welded portion with asbestos/sand. j) SIDE BEARER CASNUB bogies are fitted with RDSO approved constant contact and PU pad type side bearers riveted/bolted on bolster. k) ELASTOMERIC PAD Elastomeric pads are provided in all versions of CASNUB bogies. The main purpose of providing elastomeric pad is to reduce wheel flange wear. Elastomeric pads and metal bonded rubber type constant contact side bearer pads shall be condemned and replaced by new ones on the following grounds :- i. If the top of the bottom plates or intermediate plate in case of side bearer pads show any crack in service. ii. If any crack of more than 50 mm is developed at any surface of rubber. iii. If a bond failure giving way more than 40 mm in any direction is developed in service. iv. If any sign of crushing of rubber is noticed. v. When in free condition, the pad has taken a permanent set of the order given in Table 6.1/ respective drawing. l) BOGIE BRAKE GEAR The brake gear mainly consists of Brake Beam (with brake head and brake block assembly), equalising levers, Push rod, End pull rod, Brake Beam hangers (in CASNUB 22W(M) bogies). The pins and bushes provided are as per IS :5517-45C8 hardened/tempered and hardness of pins and bushes to be 250-280 BHN. Material for washer to be IS :2062 Fe410WA. The maximum permissible wear on the pin diameter and bush inside diameter is limited to 1.5 mm. In service as the tread diameter of wheel decreases due to wear, pins located in End Pull Rod with under frame to be relocated. In case of CASNUB 22W(M) bogies it is of cast steel and Brake head and Block assembly is a separate assembly. This assembly attached with the circular end of a cast steel Brake beam by means of a pin. In all other bogies the brake beam is fabricated. Brake beam strut and end piece casting are of cast steel. Brake head is integral part of “End Piece Casting”. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 9 of 43 m) BRAKE BEAM [IN ALL BOGIES EXCEPT CASNUB 22W(M)] AND BRAKE WEAR PLATES Bogies are fitted with unit type fabricated brake beams that slide in the guide cavity provided in the side frame. Cavities are provided with silico manganese steel liners. The brake heads are integral part of the brake beam. Brake beam is shown in WD-89033- S/1, however the brake block to WA/BG-6158 is common for all versions. CASNUB 22W(M) Bogies The bogie is fitted with unit type suspended cast steel brake beam. The brake head is a separate sub assembly which is fixed with brake beam circular end by means of pin passing through brake beam end and brake shoe adjuster along with spring loaded brake head. Assembly provides rotational flexibility to brake head. Details are shown in Drg No. WD-85084-S/1, WD-88012-S/1 & WD-86034-S/1. n) RECLAMATION OF BRAKE BEAM ON ACCOUNT OF WORN OUT BRAKE HEADS Reclamation procedure for different versions of CASNUB bogie brake beams shall be as follows. I) CASNUB 22 W(M) Bogie Brake heads are fitted on brake beam with the help of brake shoe adjuster as shown in drawing no. WD-88012-S/1. Brake heads are further secured on brake beam-ends by washer and split pin. Procedure for replacing worn out brake heads is as under; i. Remove split pin and washer from brake beam end. Remove pin securing brake shoe adjuster with brake beam by removing split pin. ii. Take brake heads out of brake beam along with brake shoe adjuster. iii. Disengage brake shoe adjuster from brake head by providing bolt after disengaging split pin, nut cover, spring and adjusting piece. iv. Assemble new brake head with brake shoe adjuster by using items mentioned in para (III) as shown in RDSO Drawing No. WD-88012-S/1. v. Slide new brake head assembled with brake shoe adjuster on brake beam end. Engage brake shoe adjuster with brake beam by using pin and split pin as shown in RDSO Drawing No. WD- 88012-S/1. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 10 of 43 vi. Further secure brake heads on brake beam end by putting washer and split pin as shown in RDSO Drawing No WD-85054-S/4. II) CASNUB 22 NL, 22NLB, 22NLM, 22NLC, 22HS, 22HS (Mod-I) 22HS (Mod-II) & IRF-108HS Bogies Brake head is integrally cast with end piece casting, which is welded with structural steel brake beam channel and Truss flat at ends as shown in RDSO Drawing No WD-89033-S/1. Depending upon the extent of wear, worn out brake heads can either be built up by welding or worn out brake heads can be replaced by new brake head. Replacement of brake head of brake beam should be done on appropriate fixture. 601 C. REPAIRS AND MAINTENANCE IN SICK LINE In order to obtain optimum life from the bogie, it is desirable to maintain the various clearances within recommended limits. Prescribed clearances are given in para 601 E. a. Due to wear of the mating components, increase in clearances should be monitored. Whenever the component reaches the condemning limits, repairs should be undertaken for either building up the wear on such surfaces or changing their liner, as the case may be. b. Due to the wear in bolster/side frame liners and wedge surface, the wedges shall move upwards. If the holes of bolster pocket wall and wedges starts crossing, repair shall be under taken. The gauge shall be used for determining the wear. c. The class of electrode, gauge of electrode, welding current and welding precautions to be taken while repairing the surfaces by welding. 601 D. REPAIR AND MAINTENANCE DURING ROH & POH In addition to all the work prescribed at para 601 C above, the following work is also to be done in ROH/POH :- a. The bogie should be dismantled during ROH. Dismantling and assembly procedure is given in para e. The bogie clearances and tolerances should be checked and rectified, if found necessary. b. Position the job for down hand welding and carry out the repairs. Ensure that suitable manipulators are used. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 11 of 43 c. After the repairs the repaired surface should be checked with relevant gauge for correctness. Excess material, if any, should be removed by grinding or machining. d. During POH of wagon in shops, bogies are to be dismantled and all the wearing surfaces of bogie shall be brought to “As New” condition. e. Assembly and disassembly of the bogie I. DISASSEMBLY  Remove shackle of centre pivot pin.  Disconnect bogie end pull rod from under frame and brake pull rod from equalizing lever to raise wagon body. Run out the bogie.  Inset assembly pin (12mm dia x 250 mm long) to retain friction shoes.  Raise bolster to touch top of side frame.  Remove outer, inner and snubber springs.  Remove assembly pins and lower wedge blocks to take them out.  Lower bolster to rest on the spring plank.  Slide the bolster to one side to take it out.  Take out the S/Frame key from side frame to release the wheel sets, adapter and elastomeric pad.  Remove the adapter retainer bolt in CASNUB 22W (M) to release the wheel sets adapter and elastomeric pad.  Take out spring plank from side frame assembly if necessary. II. ASSEMBLY After repair/reclamation and gauging of components with respective gauge, assembly of the bogie shall be done by reversing the procedure of disassembly. During assembly of the bogie following points should be taken care - (a) Matching of both load and snubber spring is important. It is recommended that springs having up to 3 mm free height variation should be assembled in same group. Mixing of new and old springs should be avoided. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 12 of 43 (b) Free height of spring / group and wheel dia for bogie assembly should be so selected such that combined drop of centre pivot should not be more than 25mm from that of new bogie. This will help in achieving proper buffer height in loaded condition. Use of 12mm and 35mm packing are also required to be provided as per existing instructions. (c) The centre pivot of the bogie shall be lubricated with about 200g – 300g graphite flakes to IS:495 at the time of assembly. No other mating surface in the bogie shall be lubricated. Important: Inspect all the load and snubber springs for proper seating after wagon body is on bogies. For detailed description of each item and its maintenance procedure, refer to RDSO publication No. G-95 (Latest Revision). 601E. NOMINAL CLEARANCES The nominal clearances and the tolerances of the bogie assembly are given below. Description 22W 22W(M) 22NL 22HS LCCF- 22W NLB, HS(MOD1), 20(C) (RETRO) NLM, HS(MOD2), NLC IRF108HS Lateral clearance between side frame 18 mm 18 mm 18 mm 25 mm 25 mm and bolster Lateral clearance between side frame 25 mm 25 mm 16 mm 16 mm 25 mm and axle box/adopter Longitudinal clearance between side 2 mm 10 mm 9 mm 9 mm 10 mm frames and axle box/adopter Longitudinal clearance between side 6 mm 6 mm 6 mm 6 mm 6 mm frame and bolster Clearance between anti rotation lug and 4 mm 4 mm 4 mm 4 mm 4 mm bolster WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 13 of 43 TABLE 6.1 WEAR LIMITS FOR BOGIE COMPONENTS Sr. Description New or Worn Wear No. Renewed Limit 1. AXLE BOX Axle Box Crown lugs (Cylindrical Roller Bearings) 159 mm 167 mm 4 mm Axle Box Crown seat (Cylindrical Roller Bearings) 36.5 mm 33 mm 3.5 mm Axle Box side lugs (Cylindrical Roller Bearings) 130 mm 136 mm 3 mm Axle Box sides (Cylindrical Roller Bearings) 268 mm 262 mm 3 mm 2. ADAPTER Adapter Crown lugs (Wide Jaw) 156 mm 164 mm 4 mm (One Side) Adapter Crown lugs (Narrow Jaw) 155.5 mm 163.5 mm 4 mm (One Side) Adapter Crown seat 3.5 mm Adapter bore seat to crown seat Wide jaw adapter 48.5 mm 45 mm 3.5 mm Modified wide jaw adapter 25.5 mm 22 mm 3.5 mm Narrow jaw adapter 26.2 mm 22.7 mm 3.5 mm Adapter Side Lugs Wide Jaw 130 136 3 Narrow Jaw 97 103 3 Adapter Sides Wide Jaw 268 262 3 Narrow Jaw 181 175 3 3. Side Frames Side frame wear friction plate 10 6 4 Side frame column sides 216 206 10 Side frame anti rotation lug 522 528 6 4. Pedestal Crown Roof Key Seat to Pedestal Crown 318 323 5 Roof 22W(M) Key Seat to Pedestal Crown 323 328 5 Roof 22NL/ NLB/HS/IRF 108HS 5. Pedestal Crown Sides and Sides of the Pedestal All Bogies – Crown Sides 152 144 4 Pedestal Sides 22W(M) 105 101 2 Pedestal Sides 22NL,NLB, HS, 81 77 2 IRF 108HS WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 14 of 43 6. Distance between Outer & Inner Pedestal Jaw of CASNUB Bogies 22W(M) 278 286 4 Pedestal Jaw (Short) for 190 198 4 22NL/NLB/HS, IRF 108HS Pedestal Jaw (Long) for 236 244 4 22NL/NLB/HS, IRF 108HS *Adapter of CTRB shall not be welded/reclaimed/renewed at any location Description New Worn Wear Limit BOLSTER Pocket 35°/270 +1° on slope Liner 8 mm 3 mm 5 mm Bolster land surface 444 mm 438 mm 3 mm Rotation stop lug 518 mm 512 mm 3 mm BOLSTER COLUMN GIBS Outer gib 234/241 mm 244/251 mm 5 mm Inner gib 136 mm 146 mm CENTRE PIVOT Wear limit vertical side - 4 mm SEAT - - 4 mm FRICTION SHOE WEDGE BLOCK Vertical Surface from Centre line of spigot 61 mm 54 mm 7 mm Slope surface by gauge - - 3 mm ELASTOMERIC PADS & CONSTANT CONTACT SIDE BEARER Type of pad Free height Condemning free height Elastomeric pad 46+1 mm 42 mm Constant contact side bearer pad A. Metal bonded Rubber pad 114+3-0 mm 109 mm B. PU side bearer (Three Rings) 142.5+1.6 mm 137 mm C. PU side bearer (Two Rings) 134+1.5 mm 128.5 mm LOAD SPRINGS Bogie Type SPRINGS Spring free height Recommended free nominal (mm) height condemning (mm) CASNUB 22 W(M), Outer 260 245 NL, NLB, NLM & NLC Inner 262 247 Snubber 294 279 CASNUB 22HS Outer 260 245 Inner 243 228 Snubber 293 278 WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 15 of 43 CASNUB 22HS(Mod-I) Outer 253 238 Inner 225 210 Snubber 304 289 CASNUB 22HS(Mod-II) Outer 253 238 Inner 222 207 Snubber 304 289 Outer 264 249 IRF-108HS Inner 246 231 Snubber 296 281 It is recommended that springs having less than 3 mm free height variation should be assembled in the same group. Mixing of new and old spring must be avoided. The bogie is fitted with two groups of long helical spring nests. The spring groups per bogie for various axle load applications are as under: Type of Bogie Axle Load Number of Springs Outer Inner Snubber CASNUB 22 W(M), 20.32t 12 8 4 NL,NLB, NLM CASNUB 22 W(M), CC+8t+2t 14 10 4 NL,NLB, NLM CASNUB 22HS 20.32t 14 12 4 CASNUB 22HS CC+6t+2t and 14 14 4 CC+8t+2t CASNUB 22HS(Mod-I) 20.32t 12 12 4 CASNUB 22HS(Mod-II) 22.32t 12 12 4 CASNUB 22NLC 25t 14 14 4 IRF-108HS 22.82t/23.5t 14 14 4 601 F. REFERENCE DRAWING NUMBERS FOR COMPONENTS Sr. No. Components Drawing No./Pamphlet No. 1. General Arrangement of Cartridge Tapered RDSO Drg. No. WD-92089-S-01 Roller Bearing (CTRB) & WD-13042-S-01/G -81 2. Worn Wheel Profile on wheel tread WD-88021 3. Wheel tread Intermediate Profile WD-89060/S-2 4. Wide jaw adapter for CASNUB 22 W, RDSO Drg. No. SK-78527 CASNUB 22 W(M) & BLC wagon Bogie 5. Modified Wide jaw adapter for Modified wide jaw adapter to RDSO Retrofitted CASNUB 22 W Drg. No. WD-85053-S/1 6. Narrow jaw adapter for all other RDSO Drg. No. WD-89067-S/9 CASNUB bogie except CASNUB 22W & CASNUB 22 W(M) 7. CASNUB 22 W(M) wheel set WA/WL-4902/WD-89025-S/1 8. All other CASNUB bogie wheel sets WD-89025-S/1 9. BLC bogie wheel sets RDSO Drg. No. CONTR-9404-S/12 WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 16 of 43 10. Leading dimension and tolerances WD-85054-S/6(22WM), WD-90042- S/1(NL,NLB,NLM,NLC), WD-92058- S/7(HS), WD-04017-S/7 (HS Mod-I &Mod-II) 11. Load bearing Springs & Snubber WD-83069-S/1(All versions except Springs 22HS Bogies) WD-92058-S/5 (22HS ), WD-04017- S/4(HS Mod-I), WD-08026-S/3(HS Mod-II) WD-98014-S/4 (IRF-108HS) 12. Springs Silico Manganese steel to IS : 3195 Gr 60 Si7 & Gr 52Cr4Mo2V and RDSO specification WD-01-HLS-94 (rev.3) 13. Centre pivot other than CASNUB 22W WD-85079-S/2 & WD-97049-S/3 14. Elastomeric Pads WD-95005-S/1 for all 15. Side Bearers R.D.S.O. Approved CCSB. 16. Brake Block WA/BG-6158 17. CASNUB 22W(M) bogie, brake beam, WD-85084-S/1, WD-88012-S/1, brake head & block assembly WD-86034-S/1 18. Brake beam [Other than CASNUB WD-89033-S/1 22W(M)] 602. FABRICATED BOX BOGIE (UIC BOGIE) Para has been deleted. If required, Wagon Maintenance Manual ver. 2001 may be referred. 603. Para has been deleted. If required, Wagon Maintenance Manual ver. 2001 may be referred. 604 & 605 Para has been deleted. If required, Wagon Maintenance Manual ver. 2001 may be referred. 606. WHEEL ASSEMBLY A. Axle An axle is a steel shaft on which the wagon/rolling stock wheels are mounted. The axle holds the wheels to gauge and transmits the load from the journal bearing to the wheels. Carriage & Wagon axle is made of steel to specification No. IRS-R-16. Its journal portion is suitably designed to mount a bearing. The axle can be divided into following portions:- i. Portion between the wheel seats called axle body ii. Wheel seat on either side. iii. Shoulders just after the wheel seat on either side. iv. Journal just after the shoulder on either side. The portion of the axle on which the wheel is pressed is known as wheel seat. The seat is fine finish machined as per drawing requirements. The shoulder portion is also fine finish machined as per drawing. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 17 of 43 Two small axle centres are drilled on end surfaces on the axle. These holes facilitate turning of the axle on centre lathes, grinding/furnishing of the journals and turning of the tyre on the wheel lathe. Axle on which bearings are mounted should have surface finish and ovality as per drawing. To facilitate the locking of bearing in position, three holes are built and tapped on each face of the axle. LIST OF DRGS. FOR AXLE OF DIFFERENT WAGONS S. Drawing No. Of Axle Type Of Wagons Nominal Wheel Condemning No. Finished Axle Load(T) Seat Dia. In Wheel Seat Dia. ** New Finished Condition** 1. WD-89025-S-02 22.9 BOXN, BCN, BRN, BOBR, BTPN, BOY 213 mm 207 mm (Fitted with CASNUB 22 NLB/ HS BOGIES) 2. WD-89025-S-02 25* BOXN EL, BOY EL (Fitted 213 mm 211 mm With CASNUB 22 NLC Bogies) 3. WD-89025-S-02 22 BLC WAGONS 213 mm 207 mm 4. SK-69601 22.9 BOBY- MARK- 210 mm 207 mm II, BOZ, BOXN (with CYL. BRG.) 5. WD-92064-S-01 22.9 BWT/A, BWL 210 mm 202 mm *Axle to Drg No. WD-89025-S-02 used in BOXN EL/BOY EL etc wagons having CASNUB NLC Bogie up to 25t axle load. ** Refer RDSO’s Letter No. MW/WA/GENL dated - 05.03.2003 & MW/25t dated- 08.08.2006 on the subject ‘Condemnation of Axles due to wheel seat dia.’. B. WHEEL The specially designed Cast or Forged steel cylindrical element that rolls on the rail, carries the weight and provides guidance for rail vehicles. Only solid wheels are in use on air brake freight stock. List of drgs. for wheels of different wagons is as under; WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 18 of 43 LIST OF DRGS. FOR WHEELS OF DIFFERENT WAGONS S.No DRAWING NO. AXLE TYPE OF WAGONS LOAD(t) 1. W/WL-4764 22.9 BOXN, BCN, BRN, BOBR, BTPN, BOY SK-68512 (FITTED WITH CASNUB BOGIES) WD-97037-S-01 OR WAP/SK/M 153 * 2. CONTR-9404-S/13 22.0 BLC WAGONS OR WAP/W-004 3. SK-69601 22.9 BOBS MK-II, BOZ 4. W/WL-4771 22.9 BWT/A, BWL 5. WD-89025-S-05 20.3 BOX, BOX MK-1, BOX MK-II, BVZC (*Cast Wheel Disc to RWF Drg. Drg. No. WAP/W-004 is also being used BLC wagons.) C. DIAMETERS OF WHEELS USED ON BG STOCK WITH CONDEMNING LIMITS WORN WHEEL PROFILE A B D E C A - TREAD DIA. B - LIMIT DIA C - RIM INSIDE DIA. D - CONDEMNING DIA. E -.. LAST TURNING SIZE DIA. Fig. 6.16 : Wheel profile WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 19 of 43 The last shop issue size and the condemning dia of different wheels shall be as per RDSO Drg.No.WD-88089/S-1 given below; S. No. Axle Drg. No. Nom. Dimensions (t) A B C D E 1. 22.9 W/WL-4764*/SK-68512 1000 897 850 906 919 2. 22.9 WAP/SK/M/153* 1000 897 - 906 919 OR WD-97037-S-01 3. 22.9 SK69601 1000 897 850 906 919 4. 22.9 W/WL-4771 915 804 761 813 826 5. 20.3 W/WL-4750 1000 851 814 860 873 6. 20.3 WD-89025/S-5 1000 851 814 860 873 7. 22.0 CONTR-9404-S-13 840 771 730 780 793 * Minimum service diameter of wheel disc in 25 T axle load having CASNUB 22 NLC bogie like BOXNEL, BOYEL etc. is 955 mm. Last shop issue size of such wheels is 963 mm. WAGON MAINTENANCE MANUAL  91 PROCEDURE OF DRAWING :- B 1. DRAW A VERTICAL LINE X-Y 65.5 2. DRAW SEMI-CIRCLE OF 14.5 R TANGENTIAL TO C LINE X-Y. 44 3. DRAW LINE 1:2.5 TANGENTIALLY TO 14.5 R SEMI- Y CIRCLE. 4. DRAW A HORIZONTAL LINE AT 28.5 mm FROM THE TOP OF THE FLANGE AND LOCATE Pt. 'A' AT WAGON MAINTENANCE MANUAL 63.5 mm FROM THE LINE X-Y. 100R 5. FROM Pt.'A' LOCATE CENTRE 'B' OF ARC OF 330 CHAPTER 6 – BOGIES AND SUSPENSION R ON A VERTICAL LINE AT 91 mm FROM X-Y. 6. DRAW ARC OF 330 R FROM CENTRE 'B'. 1 IN.52 330R 7. LOCATE CENTRE 'C' ON VERTICAL LINE AT A HORIZONTAL DISTANCE OF 65.5 mm FROM THE LINE X-Y SUCH THAT BC=(330-100) i.e. 230 mm. 1 IN 20 8. DRAW ARC OF 100 R WITH CENTRE AS 'C'. 14.5R +1 -0 R 14 9. DRAW ARC OF RADIUS 14 mm TANGENTIALLY 28.5 TO 100 R ARC AND LINE 1:2.5. 10. DRAW LINE 1:20 TANGENTIALLY TO 330 R ARC. A 63.5 SUPERSEDED BY X SUPERSEDES Dt. WORN Scale Passed Checked Drawn WHEEL PROFILE Tarced (For B.G. Wagons) J.S. No. WD-98018 4/98 WD-98018 REVISED & REDRAWN 4/98 R.D.S.O. GROUP DESCRIPTION DATE B.G. WD-88021 ALT. ITEM AUTHY ASSEMBLY DRG. (W) Page 20 of 43 FIG. No. 6.17 WORN WHEEL PROFILE CHAPTER 6 – BOGIES AND SUSPENSION Page 21 of 43 Fig. 6.18 Intermediate Profile (WD-89060/S-2), Continue………… WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 22 of 43 Fig. 6.18 Intermediate Profile (WD-89060/S-2), Continue………… WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 23 of 43 Fig. 6.18 Intermediate Profile (WD-89060/S-2) WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 24 of 43 C. RE-AXLING & REDISCING Defective axles, which cannot be repaired, otherwise, are required to be replaced. The axles requiring replacement are pressed out of the wheels discs on a Wheel Press specially designed for this purpose. After machining new axles to the required size, wheel discs are pressed on it on the press. After the wheel discs are pressed out, the bore shall be machined to specified finish as per drawings on a vertical boring machine. The depth of cut should be minimum possible, just enough to remove the irregularity of the surface and to ensure fine finish machined surface. The finish size of the bore should be taken and wheel seat of the axle should be surface finish/roughness machined accordingly to a higher diameter giving allowance for the required interference fit. The selective assembly of Wheels and axle will be done so as to obtain an interference between wheel seat and bore of 1 mm per meter (0.001 mm per mm) dia. of wheel seat and to ensure assembly pressure build-up of 400 to 600 Kg. per mm. dia. of wheel seat. During assembling process/assembly of wheel and axle shall satisfy Para -2, 3, 5 & 7 of IRS specification R-19/93 Part I. While pressing the wheel, care should be exercised to see that the pressing is stopped at a pre-marked correct location on the inner side of the wheel seat. At the time of re-axling, following points to be ensured:- i. Before mounting the wheels on axles, carefully clean the wheel seat and bore of the wheel to remove rust grit, chips and grease. ii. Coat wheel seat and bore with mixture of basic carbonate white lead and boiled (not raw) linseed oil to avoid scoring of mounting surface. iii. Keep special care so that wheel-seat and bore and not damaged during mounting operation. iv. Mounting press must have dial pressure gauge and a pressure recording gauge. v. Mount the wheels centrally on axle at a proper gauge distance. vi. Recorder must be maintained and kept properly adjusted all the time. vii. Check wheel mounting and check gauge frequently so that excessive wear does not allow improper mounting of wheels. viii.Stamp at the front Hub edge for the rediscing particulars as per RDSO Drg. No. WD-87080/S-1 to facilitate tracing of history of the wheels. ix. After mounting of wheels on axle apply rail gauge at three or more equi- distant points around the circumference to see that wheels are within gauge limits. D. TYRE TURNING OR REPROFILING To remove irregular surface on the profile caused due to wear in service re- profiling is to be done. In service some of the wheels develop defects beyond the permissible limit for the safe turning. Such wheels are to be withdrawn and should be sent to workshop for removing the defects. The wheel requiring re-profiling shall be WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 25 of 43 turned to worn wheel profile or to intermediate profile to RDSO Drg. No. WD-88021 or WD –89060/S-2 respectively. On receipt of wheels in wheel shop, the diameter of both the discs at wheel tread should be measured. Some times wheel with unequal dia. on the same axle are received. Many times skidded wheels are received due to which tyre surface at some spots gets hard. Such spots can not be machined on wheel lathes available in many workshops. Such wheels should be sent to re-profiling section for softening the hard spots on suitable designed furnaces. After softening, the wheels should be sent to tyre turning section. Tyre turning is done on a specially designed wheel lathe. The root radius, vertical inclined surface, radius on the top of the flange are difficult portions to be machined. To machine these portions, specially designed gadgets are provided on the Tool ports. While tyre-turning, the following should be kept in mind:- i. The wheel gauge, i.e. the distance between the flanges of the 2 wheels of the same axle should be within the laid down limit. The aspect has to be particularly ensured when new tyres have been fitted. On old tyres normally the distance is correct. But in some cases where the machining has not been done accurately in the past, the distance may be beyond the permissible limit. If the distance is less it can be corrected by machining the side surface of the wheel. In case the distance is more, the wheel shall required re-axling. It is very important that the turner of the wheel lathe checks this distance at the time of turning in addition to the check done by incoming Inspection staff. The laid down distance is 1600 +2/-1 mm for BG. ii. The variation in tread diameter of wheel tread/ tyres on the same axle after fresh turning on surface wheel lathe/ under floor wheel lathe/pit wheel lathe should not exceed 0.5 mm. The turner normally machines the wheels to equal diameters. However, small variation may occur if the cut has not been taken carefully. After finishing the operators should assure dia of both wheels. If the difference is more than 0.5 mm he should take another cut on the tyre having the large diameter. E. PAIRING OF WHEELS Different wheels fitted on a wagon are to be paired. Normally it is done in the Lifting section of the wagon shop. Where large number of wheels of the same type are turned on each day, no difficulty is experienced for such pairing. However, when the supply of wheels to Lifting section is from hand to mouth such pairing for the day‟s requirement has to be done in the tyre, turning section of the Wheel shop itself. Pairing in Wheel shop also becomes necessary for special tyre of wheels received in small numbers. When pairing is done in the Wheel shop, it becomes necessary to turn such wheels even to lesser diameters than is required from the point of view of wear. For such cases specific instructions should be given to turner of the Wheel lathe. The variation in tread diameter should be as per Clause 2.8.14.2 of IRCA Part III. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 26 of 43 F. WHEEL DEFECTS The wheels are required to be withdrawn from service for the following major defects:- i) Reached condemning limits ii) Flat places/skidded iii) Flanges sharp/deep/thin iv) Too insufficient radius at the root of flange v) Gauge slack/tight vi) Cracked or broken Defects i) to iv) mentioned above are detected with the help of tyre Defect Gauge. Defect as in item (v) is checked by Wheel Gauge. Defect as in item (vii) is determined by visual examination. Permissible maximum flat surfaces on tread are as under: Wagon Type Permissible Flat Surface BG Wagons 60 mm a) THIN AND SHARP FLANGE (i) For proper method of using Tyre Defect Gauge, please refer IRCA Part III. (ii) Wheel may be passed provided the minimum thickness of flange is 16 mm. (iii) Wheel must not be allowed to run if flanges are worn to knife edge but may be passed if the radius is not less than 5 mm. (iv) Wheels with too small radius at the root of flange should not be allowed to remain in service. 607. GREASE FOR CTRBs Grease to RDSO‟s Specification No. WD-24- MISC-2003 is to be used in CTRB. Before applying the grease, clean all the equipment to be used for lubrication. Apply grease to each single assembly and between the roller and cage assemblies in the quantity as given below: Amount of grease to be applied To Single Roller Assembly Between Roller Assembly Total + 30 gm (Each Cone Assembly) (Around spacer) 115 gm 170 gm 400 gm     WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 27 of 43 608. MAINTENANCE AND REPAIR OF CARTRIDGE TAPERED ROLLER BEARINGS The following are the recommended practices for long life and trouble-free operation of Cartridge Tapered Roller bearings: (a) Recommended Practices for Railway Workshops: i) Cleaning, inspection and assembly of cup & cones to be done in controlled environment to avoid ingress of dust particles. ii) 100 % checking of groove depth of seal wear ring and re-use of only correct wear ring or replace with new one. Use of seal wear rings with vent holes needs to be stopped immediately. Use of proper measuring instrument is required for seal wear ring groove depth. iii) Bearing mounting machine needs to be periodically calibrated for its proper working at specified force (50 +/- 5 Tons) with ensuring holding for specified time (5 seconds). Use of the proper fixture (tooling) needs be ensured. The pressure – force conversion configuration for the specified machine may be prominently displayed near the mounting area for the benefit of the mounting staff. iv) Checking of journal diameter at three locations with snap gauges may be enforced for ensuring specified fits to obtain the desired mounting force. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 28 of 43 v) Checking of fillet radius after proper cleaning for correct seating/ fitment of backing ring may be ensured. Backing rings with vent holes should not be reused. They should be replaced with plugged backing rings or new backing rings vi) Proper tightening of end cap screws with periodically (monthly) calibrated torque wrench at specified torque may be ensured on wheel sets. The specified torque should be maintained to 40 Kg – m (290 foot-pound). The torque wrench must be maintained with an accuracy of +/- 4% (Maximum). Minimum 2 passes and maximum 5 passes to be applied to ensure proper clamping. If any screw movement persists after 5 passes check for any irregularity. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 29 of 43 vii) Axle threads to be checked with Go- No Go gauge and Axle thread holes should be cleaned by compressed air. viii) Inside surface of Adapter is required to checked for wear on thrust shoulder and bearing seating area/adapter machined relief with proper gauges (Sample gauge is depicted below). Gauging as per G 95 may be ensured. ix) Assembly of bogie using properly checked adopter may be ensured. Railway workshops must manufacture/procure specified gauges for this checking. Cups should be checked for wear patterns seen on the cup outside diameter as it reveals excessive wear of the adapter. The figure below shows normal wear bands present on cup OD generated from a serviceable adapter. Wear bands formed due to excessively worn out adapter are illustrated below. In case of fully worn out adapter, the cup starts contacting the adapter at the ends also. Worn out adapters must be scrapped. Displaced adapters also form two distinguished marks on the cup outside diameters. And such cups must be examined for spalls being generated on raceways under the adapter contact areas. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 30 of 43 x) Checking of the mounted end lateral play may be ensured on each mounted CTRB. This is critical to bearing performance. With correct mounted lateral more roller share the load. As a result, peak load on individual rollers are less. Excessive mounted lateral causes high peak roller loads. As a result of fewer rollers sharing the load. This reduces fatigue life. xi) Welding on the wagon after lowering of bogie shall be avoided as far as possible. If any welding work is done after assembly of wagon proper earthling shall be ensured (specifically in odd hours) so that electric current does not pass through the bearings. The earthing should be done very close to welding area and the earthing wire should be tightly secured at both ends. Alternatively the earthing can be done with a earthing wire/strip running parallel to the track instead of earthing with the rails. If wagon is not properly earthed the current passing through the bearings will cause arcing in between the rollers and the raceways leading to failure. All the earthling ports may be properly grounded through periodically calibrated earth pits. One of the recommended scheme of earthing is shown below: xii) Separate investigation of defective CTRBs coming from divisions may be done. xiii) The fitment of cup and cones of same make in overhauled CTRBs may be ensured. To the extent possible they may be maintained with similar age profile. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 31 of 43 xiv) The stamping of overhauling date & workshop code may be done on backing ring of CTRB also as per RDSO letter no. MW/WA/Genl dated 26/04/2012. xv) Handling of wheel sets with proper lifting tackles shall be ensured. Use of wire slings for lifting of wheel sets may be avoided. Similarly, securing wire ropes near bearing area while pulling the wagon may also be avoided. Periodic audits of CTRB fitment/maintenance including wheel handling to be done using check sheets already circulated vide RDSO letter no. MW.CTRB.D dated 23/12/2010. (b) Recommended Practices for ROH Depots: 1. Area where bearings are opened for UST of axle must have controlled environment. 2. Proper visual examination of bearings to be done. Some important aspects to be checked are as under: 2.1 Overheating, such as discoloration or parts fused together. 2.2 Check for loose and/or missing cap screws. 2.3 Check that all tabs of the locking plate are properly bent up against the flats of the cap screw heads in the loosening direction. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 32 of 43 2.4 Inspect for damage or wear to the end cap from a displaced adapter. 2.5 Examine the bearing for welding damage or exposure to extreme heat, such as from a cutting torch. Remove the bearing from service if you find any damage. 2.6 Check for cracked or broken outer rings (also called bearing cups). WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 33 of 43 2.7 Inspect for a loose backing ring. If you can move or rotate the backing ring by hand, remove the bearing from service. 2.8 Check the backing ring for damage or wear from a displaced adapter. 2.9 Check whether the grease seal is displaced or cocked or has external damage. 3. While carrying out wheel turning, the prescribed dummy/protective covers (as mentioned in clause 6.22 & shown in Drawing No. WDIIA-8514/S-1, included in Annexure of G-81) on bearing may be used. 4. Proper tightening of end cap screws with periodically (monthly) calibrated torque wrench at specified torque may be ensured on wheel sets. The specified torque should be maintained to 40 Kg – m (290 foot-pound). The torque wrench must be maintained with an accuracy of +/- 4% (Maximum). Minimum 2 passes and maximum 5 passes to be applied to ensure proper clamping. If any screw movement persists after 5 passes check for any irregularity. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 34 of 43 5. Handling of wheel sets to be done by using the prescribed lifting tackle and not wire ropes which can damage the grease seals. 6. In case bogie(s) are dismantled for any purpose, the adapter must be thoroughly inspected for soundness and wear. Gauging must be done as specified in G 95. 7. Ensure the Adapter is properly placed on CTRB. Most bearings will “creep” in service, creating two wear bands as pictured below. This is a normal condition that also causes wear to the adapter‟s seat pads Wear bands that extend to the end of the outer ring, as shown on the left side of the image below, indicate an excessively worn adapter seat. A shiny edge at the extreme end of the outer ring, as shown on the right side of the image below, is an indication that the thrust shoulder is worn. Replace the adapter if either of these conditions exist. 8. Whenever wagons or bogies fitted with CTRBs require welding in ROH Depots/Sicklines, special attention should be paid so that electric current does not pass through the bearings. The earthing should be done very close to welding area and the earthing wire should be tightly secured at both ends. Alternatively the earthing can be done with a earthing wire/strip running parallel to the track instead of earthing with the rails. If wagon is not properly earthed the current passing through the bearings will cause arcing in between the rollers and the raceways leading to failure. 9. The stamping of overhauling date on backing ring of CTRB has been advised to be done by workshops on each overhauled bearing to ensure traceability. In case CTRBs fitted wheel are found to be overdue overhauling in course of ROH/Sick line examination to the wagon, such wheels must be sent to nominated workshop for overhauling. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 35 of 43 (c ) Recommended practices during incoming train examinations in yards 1. Detection of warm bearings on arrival of the train. Check operating temperature of the bearing by touching the adapter or underside of the bearing cup with bare hands immediately after the vehicle is halted. If it is found impossible to hold the hand for a few seconds on the adapter or the cup it means that the bearing is running hot. Cross check the bearing temperature with temperature sensing hand held pyrometers/sensors giving direct reading of the bearing. If bearing temperature is more than 90 degree centigrade the wagon should be detached and bearings should be removed from the service. 2. Check for any abnormal sound and/or grinding noise. 3. Visually inspect the bearing for defects like broken cup, loose or damaged grease seals, broken adapters, missing cap screws, broken /distorted end cap, broken locking plate. Check for loose backing rings, missing side frame key. Any of these conditions are reasons for bearing removal. 4. Checking of displaced adapters [as mentioned in clause 6.1.1(d) of G-81]. 5. Availability of adapter retaining nut & bolt in wide jaw bogies. (d) Axle Box Feeling of Freight Trains The procedure of axle box feeling is as under: 1. Axle box feeling should be done immediately after the arrival of the train and two technicians, one from the left and another from the right side should do the job. 2. Axle Box feeling must be done on the adapter or the underside of the CTRB cup. 3. Hand held pyrometers should be used for detecting the temperatures; in addition the practice of feeling the boxes with back side of palms should be followed. Such pyrometers should be calibrated regularly. The wagons with axle boxes having temperature more than 90 Degree Celsius should be detached. 4. The axle boxes having grease oozing, burning small, missing/lose end cap bolts, loose backing rings, grease seals and burnt EM pads are the indicators of potential hot box cases. The above instructions should be displayed at the axle box feeling points for the guidance of the technicians. (RDSO Letter No. MW.RB.Genl Dated 20/21.11.2012) WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 36 of 43 609. Arrangement of springs in various CASNUB trolleys according to axle load Spring nest Type of Type of Spring nest Modified Spring arrangement for wagon trolley arrangement for nest arrangement 25t axle load 20.32 t axle load for 22.9 t axle (with NLB trolley only) load (M1) EL / (BOBSNM1) BOXN BOXNR 22W, BOXNCR BCN W(M), BCNA NL, S S S S S S BOBRN NLM, BOBSN NLB, BOY BOBYN BOXNHS BOXNLW BOXNHL 22HS S S S S BOST NA BCNAHS BCNHL BOSTHS 22HS (Mod-1) S S S S NA S S S S BOXNHA IRF108HS NA BRN BRNA S S BTPN 22NLB NA NA BTPGLN WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 37 of 43 BRNAHS BFNS 22HS S S BRHNEHS NA NA BLCA/BLCB LCCF20 S S NA NA *NA= Not applicable (a) Nomenclature of Bogie: W M N L B HS Wide Jaw Modifie Narrow Jaw Light Belly shaped High Speed d weight bolster Load Bearing springs and snubber springs: CASNUB bogies are fitted with two groups of long travel helical springs nests. The spring group for bogie for various axle load application are shown in fig below. Spring details are shown in WD 89069-S/1 (Common for all versions except Casnub – 22HS Bogie). The spring details for Casnub – 22 HS bogies are shown in WD – 92058-S/5. Damping: The suspension is provided with load proportional friction damping arrangement with the help of Mn steel Cast Wedge supported on the snubber springs. The details of the snubbing arrangement are shown in fig below. INNER SPRING SNUBBE R SPRING OUTE R SPRIN G WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 38 of 43 Spring nest spring gauging (b) Grouping of Springs: (By strip method) A. Group Band (Coloured) for in service springs (Maintenance group) Matching of both, load and snubber springs, is important. It is recommended that springs having not more than 3 mm free height variation should be assembled in the same group. Coloured band should be provided for easy identification of group height as indicated in the table. All versions (except for CASNUB 22 HS) No. of Bands Outer Inner Snubber I 260-257 262-259 294-291 II 257-254 259-256 291-288 III 254-251 256-253 288-285 IIII 251-248 253-250 285-282 Red 248-245 250-247 282-279 CASNUB 22 HS Group Outer Inner Snubber I 260-257 243-240 293-290 II 257-254 240-237 290-287 WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 39 of 43 III 254-251 237-234 287-284 IIII 251-248 234-231 284-281 Red 248-245 231-228 281-278 CASNUB 22 HS (Mod-1) Group Outer Inner Snubber I 253-250 225-222 304-301 II 250-247 222-219 301-298 III 247-244 219-216 298-295 IIII 244-241 216-213 295-292 Red 241-238 213-210 292-289 B. Group Band (Coloured) of NEW Springs, Matching of both, load and Snubber springs, is important. It is recommended that springs having less than 3 mm free height variation should be assembled in the same group. All versions (except for CASNUB-22 HS) Ref: DRG No.WD-83069-S/1 No. of Outer Inner Snubber Bands I 263-261 265-263 297-295 II 261-259 263-261 295-293 III 259-257 261-259 293-291 CASNUB- 22 HS, Ref: DRG. No.WD-92058-S-5 Group Outer Inner Snubber I 263-261 243-241 293-291 II 261-259 241-239 291-289 III 259-257 239-237 289-287 CASNUB -22HS (Mod-1) BOSTHS, Ref: DRG No. WD-04017-S/4 Group Outer Inner Snubber I 256-254 228-226 307-305 II 254-252 226-224 305-303 III 252-250 224-222 303-301 ** Mixing of new and old springs should be avoided. WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 40 of 43 (c) SPRING DATA: Type of spring Coil Dia. in (mm) Free height (in mm) Condemning limit( In mm) All visions (except for CASNUB-22HS) Outer 25 260 245 Inner 16 262 247 Snubber 16 294 279 CASNUB-22HS Outer 22 260 245 Inner 18 243 228 Snubber 18 293 278 CASNUB -22HS(Mod-1) BOSTHS Outer spring 21.5 253 238 Inner Spring 16.5 225 210 Snubber Spring 16.5 304 289 WAGON MAINTENANCE MANUAL  CHAPTER 6 – BOGIES AND SUSPENSION Page 41 of 43 (d) Spring Arrangement for Various CASNUB Trolleys Speed as per speed certificate ( KMPH) Wagon type Bogie Number of springs per bogie Axle Empty Load 20.32 80 75 BOXN Casnub 22 NLB Outer -12, Inner-8, Snubber -4 22.32 80 60 22.82 80 60 22.32 80 70 BOXNM1 Modified Casnub 22 NLB Outer -14, Inner-10, Snubber -4 22.82 80 60 BOXNEL Casnub 22 NLC Outer -14, Inner-14, Snubber -4 25.00 65 50 BOXNHS Casnub 22HS Outer -14, Inner-12, Snubber -4 20.32 100 100 22.23 90 75 BOXNHSM1 Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.82 80 60 20.32 100 100 BOXNHA IRF 108 HS Outer -14, Inner-14, Snubber -4 22.1 100 100 22.82 100 75 BOXNHL Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.9 90 70 22.32 65 60 BOXNLWM1 Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.82 65 60 BOY Modified Casnub 22 NLB Outer -14, Inner-10, Snubber -4 22.86 75 65 BOYEL Casnub 22 NLC Outer -14, Inner-14, Snubber -4 25.00 65 50 20.32 75 75 BOBYN Casnub 22 NLB Outer -14, Inner-08, Snubber -4 20.32 65 60 20.32 80 75 BCN Casnub 22 NLB Outer -14, Inner-08, Snubber -4 22.32 80 75 22.32 80 75 BCNM1 Modified Casnub 22 NLB Outer -14, Inner-10, Snubber -4 22.82 80 60 20.32 80 60 BCNA Casnub 22 NLB Outer -14, Inner-08, Snubber -4 22.32 80 75 22.32 80 75 BCNAM1 Modified Casnub 22 NLB Outer -14, Inner-10, Snubber -4 22.82 80 60 BCNAHS Casnub 22HS Outer -14, Inner-12, Snubber -4 20.32 100 100 22.32 100 75 BCNAHSM1 Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.82 100 75 BCNHL Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.9 75 70 20.32 80 75 BOST Casnub 22HS Outer -14, Inner-12, Snubber -4 22.32 80 50 BOSTM1 Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.32 65 60 BOSTHS Casnub 22HS (Mod - I) Outer -14, Inner-12, Snubber -4 20.32 100 100 BOSTHSM1 Casnub 22HS (Mod - I) Outer -14, Inner-14, Snubber -4 22.32 80 60 BOSTHSM2 Casnub 22HS (Mod - II) Outer -14, Inner-12, Snubber -4 22.32 100 60 BOBSA Modified Casnub 22 NLB Outer -14, Inner-10, Snubber -4 22.9 75 75 BOBSNM1 Casnub 22 NLC Outer -14, Inner-14, Snubber -4 25.00 60 50 WAGON MAINTENANCE MANUAL  CHAPTER 6 – BOGIES AND SUSPENSION Page 42 of 43 Speed as per speed certificate ( KMPH) Wagon type Bogie Number of springs per bogie Axle Empty Load 29.32 80 80 BOBR Casnub 22 NLB Outer -14, Inner-08, Snubber -4 22.32 75 60 BOBRM1 Modified Casnub 22 NLB Outer -14, Inner-10, Snubber -4 22.32 75 60 20.32 70 75 BOBRN Casnub 22 NLB Outer -14, Inner-08, Snubber -4 22.32 65 60 BOBRNM1 Modified Casnub 22 NLB Outer -14, Inner-10, Snubber -4 22.32 80 60 BOBRNHSM1 Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.32 65 60 BOBRNALHS Modified Casnub 22 HS Outer -14, Inner-14, Snubber -4 22.32 65 60 M1 BOBRNEL Casnub 22 NLC Outer -14, Inner-14, Snubber -4 25.00 65 50 BRN Casnub 22 NLB Outer -14, Inner-08, Snubber -4 20.32 80 75 BRNAHS Casnub 22HS Outer -14, Inner-12, Snubber -4 20.32 100 100 BFNS Casnub 22HS Outer -14, Inner-12, Snubber -4 20.32 100 80 BTPN Casnub 22 NLB Outer -14, Inner-08, Snubber -4 20.32 80 80 BTPGNL Casnub 22 NLB Outer -14, Inner-08, Snubber -4 20.32 80 75 BLCA 20.32 100 100 BLBC 20.32 100 100 BLLA 20.32 100 100 BLCA LCCF 20 ( C) Outer -14, Inner-12, Snubber -4 20.32 75 75 BLBC double stock 20.32 75 75 BLCAM 22.00 100 95 BLCBM Modified LCCF 20 ( C) Outer -14, Inner-14, Snubber -4 Double stock BCACM auto car wagon LCCF 20 ( C) Outer -14, Inner-12, Snubber -4 20.32 65 65 BRHNEHS Casnub 22 HS Outer -14, Inner-12, Snubber -4 20.32 65 50 Maintenance Issues of Springs: 1. Stacking System of Springs- 4-Tier system should be adopted for easy placement & removal of springs. 2. Spring loaded dial gauges-  Spring height gauges must be kept in spring section section.  Spring loaded dial gauges may also be kept inline with NKJ depot. 3. Transportation of set of Springs For safe transportation from sub-store to shop, rectangular wheeled trolleys should be developed & kept in section ( Such trolleys are available in ROH depot TKD & NKJ). WAGON MAINTENANCE MANUAL CHAPTER 6 – BOGIES AND SUSPENSION Page 43 of 43 4. Colour Coding/Provision of Band  As of now, only local colour coding is in practice in zonal Railways.  Marking of coloured band on springs is most commonly adopted system in ROH depots. It is recommended that marking of bands may be done for easy grouping of springs in the depots. 5. Cleaning of springs  Wire brush is being used for cleaning of springs. The practice is useful & be continued. WAGON MAINTENANCE MANUAL